Method and apparatus for positioning in-wall power

ABSTRACT

The present invention discloses a method and apparatus for locating a pre-wired electrically isolated power source. The invention includes a plurality of embodiments of encased receptacles combined with recessed electrical enclosures for mounting the receptacles. The recessed electrical enclosures allow for the input and output receptacles to be mounted externally to the enclosure, to create space internal to the enclosure, for visual isolation of receptacle outlets and associated plugs/connectors that may also be present in the enclosure.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 61/516,768 filed 7 Apr. 2011 and U.S. Provisional Application No. 61/630,677 filed 16 Dec. 2011.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to a method and apparatus for locating a pre-wired electrically isolated power source. The invention includes a plurality of embodiments of encased receptacles and recessed electrical boxes for mounting these embodiments.

SUMMARY OF THE INVENTION

The foregoing and other problems are overcome, and other advantages are realized, in accordance with the disclosed, alternative embodiments of these teachings.

The power solution of the present invention comprises female and male receptacles combined with an integrated enclosure that can be used in applications where power must be supplied to a remote unit, such as a flat panel TV being hung on a wall (behind wall installation), or in a remote location where an integrated enclosure is necessary for installation and electrical isolation (trade show/outdoor exhibit where remote power is utilized on a temporary wall fixture).

For behind wall installations the invention may combine isolated power receptacles in combination with “Deep Box” mounting enclosures. The “deep box” enclosures allow for the input and output receptacles to be mounted deep inside a wall for visual isolation of receptacle outlets and associated plugs/connectors that may also be present in the enclosure.

In a behind wall installation, the integrated enclosures containing the female and male receptacles are separated behind a wall such that power can be supplied to the female end from an external source (such as an extension cord) which will supply power to a male receptacle mounted interior to the wall. The integrated enclosures for the receptacles are necessary to facilitate mounting in a variety of forms. Both the power input (female end) and power output (male end) integrated enclosures may contain a mounting frame for installation directly to a wall surface or onto any type of faceplate or in-wall enclosure, such as the “deep box” mounting enclosures of the present invention.

Alternatively, the integrated enclosures may be sold pre-mounted to any in-wall enclosure, including the “deep Box” enclosures of the present invention. Further, the integrated enclosed receptacles, interface wiring, and associated mounting frames or boxes (deep box or conventional electrical box) may be sold as a kit to facilitate easy installation. The electrical connection between the integrated enclosures may be separable via a snap plug or the like.

The integrated enclosures facilitate mounting of the power output and power input to a variety of electrical boxes including standard electrical boxes, flush mounted wall plates, and “deep boxes” disclosed in the present invention. Since the receptacles are encased, they are not required to be mounted internal to an electrical box for electrical isolation. This allows for the receptacles to be mounted externally to the electrical box enclosure, creating additional space within the box necessary for hiding connectors and the like. The encased receptacles may also be rough mounted to any wall surface.

The power input and power output integrated enclosure may be formed by overmolding, be a one piece boot, a two piece joinable encasement, or may comprise an integrated enclosure built around an overmolded connector. The receptacles are electrically connected within the integrated enclosure at the factory and the electrical coupling between the enclosures can be ordered in specific lengths to meet the needs of a particular installation.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and other features of the present invention are explained in the following description, taken in connection with the accompanying drawings, wherein:

FIG. 1 illustrates an embodiment employing the principles of subject invention denoting encased receptacles as encased power input and power output with an electrical interface as any length necessary for a particular installation.

FIG. 2 illustrates the embodiment of FIG. 1 having faceplates for connection to the encased receptacles.

FIG. 3 illustrates the embodiment of FIG. 2 illustrating the installation of the encased receptacles, electrical interface, and faceplates in a wall. Also illustrated is an existing power receptacle with an extension cord for routing available power to the encased power input receptacle via an extension cord.

FIG. 4 illustrates an alternative embodiment for the design of the encased receptacles 10 and 20.

FIG. 5 illustrates a mounting frame utilized in the current invention.

FIGS. 6-7 illustrates an IEC power receptacle integrated into the mounting frame of FIG. 5.

FIG. 8 illustrates a frame support member utilized in the current invention.

FIGS. 9-10 illustrates the assembled mounting frame and frame support member of FIGS. 5 and 8.

FIG. 11 illustrates a housing embodiment of the encased receptacles of the subject invention.

FIG. 12, illustrates the assembled mounting frame and frame support member of FIGS. 7,8 and 11 prior to final assembly.

FIG. 13 illustrates a boot embodiment of the encased receptacle of the subject invention.

FIGS. 14-16 illustrate a joinable section embodiment of the encased receptacle of the subject invention.

FIG. 17-19 illustrates a single gang recessed electrical box of the present invention.

FIG. 20-21 illustrates a double gang recessed electrical box of the present invention.

FIGS. 22-23 illustrates an alternative embodiment of a recessed electrical box of the present invention.

FIGS. 24-26 illustrates an encased receptacle of the present invention in combination with a recessed electrical box of the present invention.

FIG. 27 illustrates an encased receptacle of the present invention in combination with a recessed electrical box of the present invention mounted to a wall.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

While certain embodiments of the present invention have been illustrated and described herein, the present invention should not be limited to such illustrations and descriptions. It should be apparent to those skilled in the art that changes and modifications may be incorporated and embodied as part of the present invention and are within the scope of the claims. It is understood that the “deep box” embodiments disclosed can also be utilized with “low voltage” receptacles connected thereto.

As seen in FIGS. 1-4, the integrated enclosure in the form of an encased power output 10 and encased power input 20 are illustrated as connected by an electrical coupling 15.

Coupling 15 contains the electrical connections between power input 20 and power output 10, including combinations of hot, neutral and ground conductors encased in any electrical interface conduit as required by applicable building codes.

The assembled In-Wall power apparatus 30 is purchased for particular applications with a fixed length electrical coupling 15. In the alternative, encased power input 20 and power output 10, can each contain a fixed length electrical coupling to be connected on-site. Each coupling may be a mating connector or bare wire to be connected during installation. Such an embodiment would facilitate selling components separately.

The encased receptacle embodiment (both power input and power output) and coupling 15 are electrically insulated to meet applicable building codes and further to be installed by a laymen without the need for a licensed electrician.

The encased receptacles 10 and 20 further include mounting frames 60A. The frames may be overmolded, or externally affixed to receptacles 10 and 20. The Mounting frames include tabs 25 including tab connection holes 25A, 25B, 25C, and 25D. Although connection holes 25A-25D are disclosed other connection holes could be included in tab 25. In the preferred embodiment, the mounting frames 60A are substantially co-planer with the front face of receptacles 10 and 20. The selection of holes 25A-25B in the embodiment of FIG. 1-4 is to illustrate the utilization of faceplates 35 and 40. Other mounting frames and tab configurations may be utilized to meet specific installation requirements. Encased standard NEMA, standard duplex, and non-standard custom receptacles require different dimensioned mounting frames and tabs.

FIG. 3 illustrates the power apparatus 30 of the present invention affixed to the surface of an exterior wall 45. In the present example, a hole would be cut in the wall for placement of receptacle 10 in an elevated location on the wall 45. Even without installing decorative faceplates 35 and 40, the receptacles 10 and 20 can be installed, as is, in wall 45 by screwing or nailing into the receptacles 10 and 20 via holes 25-thru 25D into wall 45. First, two holes would be made in wall 45. Next, Receptacle 20 would be “fished” down to the first hole and receptacles 10 and 20 would be secured within the openings. Preferably, receptacle 20 would be at floor level out of view and in the vicinity of a live power outlet 50 as illustrated in FIG. 3. Live power would then be supplied to receptacle 20 via a conventional extension cord 55. Power would then be available to receptacle 10 for powering, for example, a flat panel TV (not shown) mounted over receptacle 10.

For a more decorative installation, faceplate 40 could be placed within the opening, connected to receptacles 10 and 20 via screw or nails through holes 25D and 40A, then faceplate 35 could be placed over receptacles 10 and 20 and connected over faceplate 40, via screws or nails through holes 35A and 25B. Receptacles 10 and 20 would be accessible through opening 35B of faceplate 35.

FIG. 4 illustrates an alternative embodiment for the design of the encased receptacles 10 and 20.

Other configurations of installations are possible, as described herein, such as recessed power input and power output within a walls interior surface.

An alternative embodiment of encased receptacles 10 and 20 in combination with recessed electrical boxes 120 is illustrated in FIGS. 24-27. It is understood that all embodiments of encased receptacles 10 and 20 described herein are mountable to all embodiments of the recessed electrical boxes described herein.

Various embodiments of recessed electrical boxes for encased power input 20 and power output 10 are contemplated, provided the encasement ensures electrical isolation and can meet applicable building codes.

As illustrated in FIG. 12, an encased receptacle is formed around an IEC power input connector 64. It is contemplated by the present invention to include other connector types to be encased including standard NEMA, standard duplex, and non-standard custom connectors. Referring to FIGS. 5 and 8, a mounting frame 60 includes opposed tabs 25, an opening 60D to receive an IEC power receptacle 64 therein, and openings 60B and 60C to receive stanchions 65A and 65B of frame support member 65.

As illustrated in FIGS. 6 and 7, IEC 64 fits snugly into opening 60D, and includes a surface extension 64A which may be further secured to frame 60 by any means known in the art (Gluing etc). Frame support member 65, including stanchions 65A and 65B, snugly engage through openings 60B and 60C (FIGS. 9-10), for engagement into housing aperatures 80 (FIG. 11), of housing 75. As illustrated in FIGS. 9-10, stanchions 65A and 65B are snugly fit, and frame support member 65 and mounting frame 60 may require gluing or the like to remain securely affixed.

To assemble the integrated enclosure, screws or similar means 82 engage housing aperatures 80A and stanchion aperatures 67 to couple housing 75 to frame support member 65.

In an alternative embodiment a molded boot 90 (FIG. 13) can be used to create an encased receptacle. In the above example, the boot 90 could be substituted for housing in glued or sealed contact with mounting frame 60 of receptacle 100. As illustrated in FIG. 13, the boot 90 would include a rearward aperature 90A for routing interface coupling 15. FIG. 13 illustrates a commercial power output receptacle 100 and boot 90, however, it is understood that boot 90 can be used also in the application illustrated in FIG. 12.

In yet another alternative embodiment, as illustrated in FIGS. 14-16, first and second mirrored joinable sections, 110 and 115, can be used to create the encased receptacle. The identical sections may include engagement tabs 115A and 115B. One of the tabs 115A may engage a recess 65AB of stanchions 65A and 65B while another tab 115B slideably engages a stanchion support member 65AC. This engagement allows for joinable sections 110 and 115 to be fixedly coupled to stanchions 65A and 65B while being joined together by screws 82. It is understood that any combination of similar structure for engagement tabs and recesses can be used to fixedly couple the joinable sections.

FIGS. 17-19 illustrate various embodiments of recessed electrical boxes or “deep Boxes”, that can be utilized with the present invention. Referring to FIG. 17-19, the single gang recessed electrical box 120 includes an integrated face plate 122 with a flange 122B that extends outward beyond the periphery of box 120A. The box 120 includes wall mounting claws 124 that are adjustable to engage drywall or the like via positioning screws 122A. The box includes connection aperatures 120B for securing any of the various embodiments of encased receptacles discussed herein. Opening 120C is approximately dimensioned to the dimensions of the receptacle ends of the integrated enclosures after flush mounting over opening 120C, and is smaller than opening 120D. As illustrated in FIG. 18, recessed box 120 includes an interior surface that projects rearward of opening 120D up to a rear panel 120E. Rear panel 120E extends inward from sides 120F of the interior surface.

Since the electrical receptacles are electrically isolated in one of the various forms described herein, they can be mounted external to recessed electrical box 120, as illustrated in FIGS. 24-26. This creates a deep opening within the wall, as illustrated in FIG. 27.

As illustrated in FIG. 26, a larger front opening 120D is of sufficient length and width to allow access to the flush mounted receptacles 10 located inward of opening 120D. As illustrated in FIG. 27, in the field, a hole would be cut in the wall at a dimension less than the periphery of face plate 122, flange 122B. Utilizing the engagement claws 124 against the interior wall mounting surface 45B by turning the positioning screws 122A, the claws would force the Flange 122B against the wall for a secure fit.

FIG. 20-21 illustrates a double gang “deep box” having the same functionality for the respective elements as described above, and further illustrates multiple openings 120C, in rear panel 120E. FIGS. 22-23 illustrate an alternative embodiment of the double gang recessed electrical box having the same functionality for the respective elements as described above. 

1. A power feed device, comprising: An encased power input in communication with a mounting frame disposed thereon, said power input for receiving electrical power supplied thereto; An encased power output in communication with a mounting frame disposed thereon, said power output for delivering power to an electrical device; said encased power input and power output having an electrical interface therebetween, said power input and power output mounting frames for positioning said power input and said power output on a wall.
 2. A power feed device as in claim 1, wherein said encased power input has a front face substantially coplanar with said encased power input mounting frame and said encased power output has a front face substantially coplanar with said encased power output mounting frame.
 3. A power feed device as in claim 1, wherein said electrical interface comprises solid copper conductors.
 4. A power feed device as in claim 1, wherein said electrical interface further comprises a mating connector, said mating connector for disconnecting and connecting said electrical interface.
 5. A power feed device as in claim 1, wherein said received electrical power is supplied to said power input through an extension cord, said extension cord receiving power from an external source.
 6. A combination power feed and recessed electrical box, comprising: first and second electrical boxes, said first and second boxes each having a first opening and a second opening; said first and second electrical boxes comprising an interior surface having sides that project generally rearward from said first opening up to a rear panel; said rear panel extending inward from each side of said interior surface, said rear panel comprising a smaller second opening, said rear panel having a first surface in communication with said interior surface and a second surface external to said first and second electrical boxes; an encased power input in communication with a mounting frame disposed thereon, said power input for receiving electrical power supplied thereto, said power input mounting frame affixed to said exterior surface of said rear panel of said first electrical box, said power input accessible through said wall first opening and said panel second opening of said first electrical box; An encased power output in communication with a mounting frame disposed thereon, said power output for delivering power to an electrical device, said power output mounting frame affixed to the exterior surface of said rear panel of said second electrical box, said power output accessible through said wall first opening and said panel second opening of said second electrical box; said encased power input and power output having an electrical interface therebetween.
 7. A power feed device in combination with a recessed electrical box as in claim 6, wherein said first and second electrical box rear panels comprise a plurality of smaller second openings.
 8. A power feed device in combination with a recessed electrical box as in claim 6, wherein the perimeter of said first opening of said first and second recessed electrical boxes further includes a flange, said flange extending outward from said first opening perimeter.
 9. A power feed device in combination with a recessed electrical box as in claim 6, wherein said first and second electrical boxes further include an exterior surface, said exterior surface further comprising at least one engagement claw mounted thereon, said engagement claw for securing said power feed and recessed electrical box to a wall.
 10. A power feed device in combination with a recessed electrical box as in claim 6, wherein said first electrical box includes at least one first electrical box and said second electrical box includes at least one second electrical box.
 11. A power feed device as in claim 1, wherein said encasement of said power input and said power output is a boot, said boot dimensioned to slide over and seal said power input and power output.
 12. A power feed device as in claim 1, wherein said encasement of said power input and said power output is an overmold, said overmold dimensioned to electrically isolate said power input and power output.
 13. A power feed device as in claim 1, wherein said encasement of said power input and said power output is a housing, said housing having two halves and joined at their center, said housing dimensioned to electrically insulate said power input and power output.
 14. A power feed device as in claim 1, wherein at least one of said encased power input and encased power output include a electrical box affixed thereto, said electrical box having an interior cavity and an exterior surface, said mounting frame of said at least one of said encased power input and encased power output affixed to said exterior surface, said at least one of said encased power input and encased power output accessible through said interior cavity.
 15. A power feed device in combination with a recessed electrical box as in claim 9 for providing a hidden power feed throughout the interior of a wall, the wall having an interior hidden surface and exterior visible surface wherein said engagement claws of said first and second electrical boxes are adjustable inward towards said wall interior hidden surface forcing said flange towards said exterior visible surface to seat said flange and secure said first and second electrical boxes within said interior of said wall.
 16. A power feed device as in claim 1, wherein said power input and power output further include a faceplate mounted thereon, said faceplate having an opening for access to said power input and power output.
 17. A recessed electrical box comprising, a first opening and a second opening; an interior surface having sides that project generally rearward from said first opening up to a rear panel, and an exterior surface; said rear panel extending inward from each side of said interior surface, said rear panel comprising a smaller second opening, wherein the perimeter of said first opening of said first and second recessed electrical boxes further includes a flange, said flange extending outward from said first opening perimeter.
 18. A recessed electrical box as in claim 17, wherein said rear panel comprises a plurality of said smaller second openings.
 19. A recessed electrical box as in claim 17, wherein said exterior surface further comprising at least one engagement claw mounted thereon, said engagement claw for securing said recessed electrical box to a wall, said wall having an interior hidden surface and an exterior visible surface.
 20. A recessed electrical box as in claim 19, wherein said engagement claws are adjustable inward towards said wall interior hidden surface forcing said flange towards said exterior visible surface to seat said flange and secure said electrical boxes within said interior of said wall.
 21. A recessed electrical box as in claim 17, wherein said rearward projecting sides project rearward at an angle.
 22. A power feed as in claim 6, wherein said encased power input and said encased power output of said first and second electrical boxes have a front face substantially coplanar with said rear panel first surface, said encased power input and said encased power output projecting away from said second external surface to create space internal to said electrical boxes.
 23. An encased power receptacle, comprising: A mounting frame having a first opening and at least one second opening therein, said mounting frame having a front and rear surface; A power receptacle positioned within said first opening, said power receptacle having a front face and rearward extending body, said front face substantially coplanar with said mounting frame front surface; A frame support member having a front and rear face, and a first opening, said rear face having at least one outwardly extending stancion, said stancion engaging said at least one second opening of said mounting frame, up to a point when said rear face rests against said mounting frame front surface, said frame support member first opening in communication with said mounting frame first opening, said power recepticle front face substantially coplanar with said frame support member front surface; A housing having at least one aperature to snugly receive said outwardly extending stancion, said outwardly extending stancion received up to a point where said housing is sealed against said mounting frame.
 24. An encased power recepticle as in claim 23, wherein said housing further comprises first and second joinable sections.
 25. An encased power recepticle as in claim 24, wherein said at least one outwardly extending stanchion further include recesses thereon, said first and second joinable sections further including outwardly extending tabs, said tabs engaging said recesses to slideable engage said joinable sections.
 26. A power feed device as in claim 1 wherein said encased power input and said encased power output is selected from the group consisting of a standard duplex device, a standard nema device, or a non-standard device.
 27. A kit for positioning remote power comprising: An encased power input having an electrical extension cut to a specific length; An encased power output having an electrical extension cut to a specific length; Said encased power input and power output adapted to be mounted to a wall.
 28. A kit for positioning remote power as in claim 27 further including a faceplate for mounting said power input and power output flush to a walls surface.
 29. A kit for positioning remote power as in claim 27 further including at least one recessed box, said encased power input and encased power output adaptable for recessed positioning within a wall interior, said power input and power output mounted externally to said at least one recessed box.
 30. A kit for positioning remote power as in claim 27 wherein said electrical extensions include a mating plug.
 31. A method of locating a power feed device, comprising the steps of: Cutting a first power input hole in an exterior wall and a second power output hole in an exterior wall; Feeding an encased power input, and encased power output, and an electrical coupling interface, throughout the interior of said wall; Affixing said encased power input in said first power input hole and affixing said power output in said second power output hole.
 32. A method as in claim 31, further including the step of providing power to said encased power input.
 33. A power feed device as in claim 1, wherein said power input further comprises a male receptacle, said male receptacle receiving power from an external source, and said power output further comprising a female receptacle.
 34. A power feed device as in claim 33, wherein said external source is a powered extension cord.
 35. A power feed device as in claim 1, wherein said power input and power output are electrically coupled by hot, neutral and ground conductors.
 36. A power feed device as in claim 1, wherein said power input and power output are electrically coupled by hot and neutral conductors.
 37. A power feed device as in claim 1, wherein said electrical interface is encased in an electrically insulated conduit.
 38. A power feed device as in claim 1, wherein said mounting frame of said power input and said power output are encased. 